As a TPM consultant in continuous process manufacturing, working closely with storeroom and purchasing leadership has been essential in determining the criticality of each of plant asset and deciding which critical spares to keep in inventory in the storeroom. Maintaining OEE through availability and running at optimum process speed is essential for profitability but so is having the lowest value possible of parts in inventory. Too often I see say 5 years-worth of bearings or couplings on a shelf when at the same time the maintenance manager is struggling to find budget to buy some other component or service.
Materials and Spare Parts Management
Making the decision to shift maintenance operations from manual methods to software is a huge step. The process can also be overwhelming and confusing for many professionals especially if you have had little to no experience with maintenance and asset management software in the past.
In today’s fast-paced industrial landscape, minimizing downtime is crucial for businesses to maintain productivity and profitability. Equipment breakdowns, maintenance delays, and inefficient processes can lead to significant downtime, resulting in lost revenue and increased costs. However, with the right tools and strategies in place, such as a Computerized Maintenance Management System (CMMS), organizations can effectively reduce downtime and optimize their operations.
Criticality analysis is a structured process to quantify how important an asset is to the organization by determining the level of risk specific failure modes pose. Criticality analysis is used extensively in high-risk industries like petrochemical, mining and chemical processing. By varying the level of detail, any organization can use the process to reduce risk and lower overall manufacturing costs.
Computer aided facility management (CAFM) is the utilization of computer software and technology to assist facility managers in planning, executing, and monitoring various aspects of facility management. This powerful tool empowers organizations to optimize their facility operations, reduce costs, and enhance productivity. By integrating data, automation, and analytics, CAFM enables facility managers to make informed decisions and efficiently allocate resources.
When it comes to managing a solar photovoltaic (PV) farm, there are a lot of factors to consider. From maintenance and repairs to managing assets and optimizing performance, it can be a complex undertaking. Fortunately, there are tools available that can help streamline these processes and improve operational efficiency. One such tool is a Computerized Maintenance Management Software system (CMMS) with a mobile version for your solar power farms.
No other element of the technical database provides as much value to planning as an accurate bill of materials. Bills of material are a list of parts that are used on the equipment. When developing BOMs, focus on parts used for routine maintenance, repair, and operation of the equipment. Individual parts should contain a minimum amount of information including: a consistent and organized name, manufacturer and their item number, price, lead time, and quantity needed for the equipment.
The new expectations from O&M teams require a more conscious approach to the tools in their armory, starting with process digitization to improve operational transparency for all stakeholders. This translates to smoother records, communication, and eliminates guesswork when it comes to data.
The consistent use of accurate engineering standards represents a huge opportunity to simplify the planning process. Engineering standards cover a wide range of topics from design to operation and maintenance activities. Many already exist and are commonly used across industries. Plant-specific standards take an initial time investment to create, but once written can be reliably used to speed up the planning effort, provide clear instructions to work crews, and help standardize critical and frequent activities.